Strain relief and switch assembly



Patented Feh, l

UNITED STATlj-:f-s`

.l l,2,272,164 STRAIN RELIEF AND SWITCH ASSEMBLYy Henry A.A Neil, Barringtom'lll., and BobertK. V

Schelke, Richmond, Ind., 'assignors to Belden Manufacturing Company, Chicago, Ill., a corporation o! Illinois y Application August 1,1s4o,'servla1 No. 349,320 n 14 claims. f (cl. vzoo-157) Our invention relates, generally, to combined strain relief and non-rigid switch support units particularly adapted for use in conjunction with portable or semi-portable electrical appliances, as, for example, vacuumv cleaners, electrically powered tools, and the like.

For convenience of Aoperation, devices. of this type are usually provided with a switch adjacent the handle or other grasping means, and because of the portability of the devices, it is practically essential thaty the connectorco'rd be equipped witha strain relief. Heretofore, it hasbeen the usual practice to provide entirely separate switch support and strain relief means. For example, in one widely used construction the switches have been rigidly mounted in or on the handles' of theA devices, while a strain reliefhas been provided by molding a suitable enlargement on the cord conductor which cooperatively lengaged theframe of the device. f

This and similar arrangements have however,

`proven unsatisfactory in certain respects. The

separate switch support andstrain relief Qis expensive and more important than that, .the'usual rigid mounting of these switches has resulted in considerably annoying breakage ofswitches and electrical cord connections thereto during` use, with accompanying. dangerto the operator and. to the equipment' as ya result of the short circuiting or grounding of the electrical circuit. The

present .invention overcomes these difficultiesl by providing a combination switch support and,

strain relief, so designed that a resilient non'- rigid support is provided forthe associated switch at all times. This resilient supporting ofthe switch by the device of the present invention also compound; and, generally the provision o f an improved Acombination strain relief and non-rigid I switch support which can be manufactured at low f cost upon existing machinery.

The various novel features and advantages of the combined strain relief and non-rigid switch support of our invention will be made m-ore apparent by reference to the accompanying drawings and the following ydescription of certain em- ]bodiments thereof. In thev drawings:

f Figure lis a fragmentary view, partially in verf ticalsection, showing a combination strain relief and. non-rigid switch support embodying the features of the present invention, installed in the handle of a vacuum cleaner;

Figurel 2 is a sectional View taken on line 2,-2 of Figure 1; f

Figure 3 is a perspective view of the combined strain relief and switch support illustrated'in Figures 1 and2;y y Figure 4 is a front elevational view of the upper end of the tubular part of thevacuum cleaner r handle shown in section inFigures 1 and'2;

vFigure 5 is a fragmentary, sectional view, partially in elevation, illustrating a modified form of the combined strain relief and non-rigid'switch support, or the present invention;

` Figure 6 isa fragmentary perspective view of 'i vthe combined strain relief and switch support shown in Figure l5; A, vFigure 'l is Aa fragmentary perspective of a second modified form of the combined strain relief and non-rigid switch supportof our invention;

provides an additional relief function whichserves to further minimize cord breakage dueto physical shock.

The principal object of the present invention, as previously indicated, isto'provide a combination strain relief and non-rigid switchr support for use with appliance connector cords. Other objects of -our'invention' include the provision of a combination strain relief and non-rigid switch support which can be applied-.to connector cordsv by a simple molding operation; the provisionof a combination strain reliefi and non-rigid switch support which can be accurately and securely positioned with4 respect to the apparatus with which it is to be usedwithout the" use of any screw fastenings or similar means; the provision of an unbreakable combination strain relief and non'-` rigid switchfsupport which can be manufactured v Figure 8 is a partial vertical sectional view itaken on line 8-8 of Figure 6;

"Figure 9 is a horizontal sectional view, taken on line 9-8 of Figure 1,0, illustrating another embodiment of the combined strain reliefand non-rigid switch support of our invention. y"I'his port of our invention which is adapted to serve as part of the handle of apower tool;

Figures l2 andA 13 are sectional views takenv f onlines I2-'|2 and l3-l3 respectively of Figor a yieldable material, such as rubber or rubber 5e ure k11;

v Figure 14 is a fragmentary, ypartial verticalv sectional view of a combined strain relief and non-rigid switch support unit forming part of another form of power tool handle and illustrating still another embodiment of my invention; and,

Figure is a sectional view taken on line Il-II of Figure 14.

The combined strain relief and non-rigid switch support-of the present invention constitutes a suitably shaped member which is adapted to be permanently attached to the appliance end of an electrical connector cord. The deviceincludes means for supporting a switch,

means for receiving a conductor cord land for mechanically connecting that cord to the de- 4 vice, and means formed integrally therewith for attaching the device to the appliance ywith which it is to be used. Preferably. the device is molded, in its entirety, of a resilient, yieldable, rubber molding compound, although, as will later appear, portions of the device may be made of rigid material. It is also preferred that the device shall be formed, as by a molding operation, di,- rectly onto the cord with which it is to .be used, this arrangement producing the most satisfactory mechanical connection to'the cord and at the same time being less expensive than other arrangements. It will be understood, however that the device may be adhesively attached in integral relationship to cords of certain types.

The combination'strain relief and non-rigid switch support indicated generally at lin Figures 1, 2, and 3 of the drawings, is particularly designed for use in connection with vacuum cleaners. The device includes an elongated, generally rectangularly shaped, body portion 2 |v and y a tubular conductor cord receiving portion or sleeve 22 which extends downwardly Afrom the lower end of the body portion2|,` as illustrated particularly in Figures l and 3.

The body portion 2| is provided with a suitably shaped recess or cavity .2,3 for receiving the switch 424 with which the device is used, and includes a suitable opening or window '25 through which the switch operating handle 2li` may extend.. The conductor cord receiving sleeve 22 is preferably of tapered construction, as shown;

in order to render it more flexible. Both the body portion 2| and the conductor cord receiving sleeve 22 are preferably molded as a single unit directly onto a duplex conductor cord 2l, as illustrated at 2l and if desired the two Wires making up the cord may be separated Within the body portion 2|, as illustrated at 28. body portion 2| and the sleeve 22 as a single unitary molding operation is very economical from a manufacturing viewpoint, and at the same time, it provides a very excellent mechani- -cal connection between the conductor cord 21 and the combination strain relief and switch support member 2li.

as will oe noted particularly in Figures 2 and 3, the opposite side Walls of the body portion 2| curve inwardly along an arc having preferably y substantially the same radius of curvature as the.

Byvirtue of this arrangement, the body 24 in the switch support or body portion 2| .and for holding the combined switch support and strain relief 2l in place in the vacuumcleaner handle 20.

The device illustrated in the drawings is so proportioned, and. it willbe seen that the rear portion of the switch 24 abuts against the inner wall of the handle at 22. thereby pressing the arcuate side walls of the body portion 2| into engagement with the portions of the handle 2l immediately adjacent the slot 2|. Due to the fact that the body portion 2| is made of resilient material. a secure, tighty fit can be readily obtained by this interlocking arrangement.

To provide a nnished appearance and to further aid in positioning the combined strain relief and switch support 20, the body portion 2| is provided with longitudinal ribs 32 adapted to be located on the outside of the slot 3| in the handle as illustrated in Figure 2.

The entire device, including the switch 24, may be conveniently held against longitudinal movement in the slot 2|- by the fastening means used for attaching the usual curved upper portion 34 of the cleaner handle tothe tubular portion of the handle 20. `This is illustrated in Figure 1, where Athe lower reduced diameter portion 33 of the curved'handle 34, which isusually wood or a a molded composition extends into theupper end Molding the of the tubular portion ofthe handle 30, and is held in place by means of the usual ferrule 36 and a double ended screw 31 (Figure 4) passing therethrough. The lower end .of the curved handle portion 34 abuts against the upper end of the combinedl switch support and strain relief 20 and thereby holds it in the position shown in Figure .Again due to the resilience of the switch support and strainrelief 20, a tight fit may be readily secured at this point without introducing any diiilculties incidental to close manufacturing tolerances. l

, The switchl 24 illustrated in the drawings is of the single-pole, single-throw type, and the connector cord 21 is of the double conductor type. It will be understood that other types of switches and connector cords may be utilized, as desired.

The combined strain relief and `non-rigid switch support of the present invention may take various forms and may, ofcourse, `be utilized in connection with other appliances than vacuum cleaners. One such devicev is illustrated at 40 .in Figures 5 and 6,` and comprises a resilient molded housing 4| which'serves both to support a switch 42 upon a rigid platemember 43 and, in connection with the sleeve 44 molded integrally with the housing 4|, to mechanically connect the associated conductor rcord 45 to the same plate member 43. The cordreceiving sleeve 44 vformed at the lower end of the housing 4| is similar in design and function to the sleeve 22 of the previously described embodiment.

The device is adapted to be mounted on the plate support 43 to be secured. in yieldable relationship thereto by means of an integral overturned lip 46 which projects from the left hand y side of the housing 4| to form a groove 48 which has the same outline and dimensions as a cooperating opening 4'| provided in theplate 43. The operating handle 50 for the switch 42 extends through an opening 49 located centrally of the lip 46. f

In manufacture the combined strain relief and switch support 40 is molded as a unit directly onto the conductor cord -4.', and the separated conductors 5| and 52 thereof. The free ends of v12 so as to conform to the shape `thereof andfbe the separated conductors 3| and 52are ofsuch length that they may be conveniently connected to the `electrical parts asrequired. The switch, vis insertedinto the housing 4| byspreadir'igan opening 53 provided in the right side thereofi in water-tight relationshipvtherewith.. y,Although The combined strain relief and switch support '40 is preferably formed .of a resilient material,

such as a rubber molding compound, and itrwill be advantageous to have the integrallip 46 formed of a rather stiff material to give added mounting strength. The assembled device may be readily mounted on the plate support 43yby deforming the lip 46 .to a sufcient extent to allow it to be inserted through the opening in the support 43. 3

Another embodiment of our inventionv also adapted for Iuse in connection with a plate type support is illustrated at 54 in Figures k'I Vand 8. This device comprises a resilient generally barrel shaped, housing 55 ymolded onto a conductor cord 51' which passes completely therethrough. A

single pole. single throw switch 59, connected in series with one of theconductors makingup the cord 51,y is disposed within the housing 55 with its operating handle 5| projecting therefrom. An annular groove .62 is provided in the periphery of the housing 55 for engagement with a plate or other support means 63. The plate support means 63 is Vprovided with an opening of the same outline and dimensions as the groove 62, and the device is installed simply by forming the right handend of the housing' 55 into this n opening in the plate support means. The housting should be made ofa relativelystii resilient material so that a strong'connection will be provided between the combined strain relief and switch support unit and the support member 63,.

It is frequently necessary or desirable to provide/for mounting a switch in water proof relationship on a panel or similar member. In Figures 9 and 10, a combined strain relief and switch the'un'it 1l is boltedirather' tlghtly'to theV legy 12,- it will-befvr seen thatthe connection therewithis not rigid,l but that appreciablev resilient movement is permitted. Thus, breakagev due to shock lis substantially eliminated. 1

In recent years extensive use has been made of portable power tools,- such as, drills, screw drivers.

t and the like. In Figs. 11, 12,` and 13 there is illustrated at r'81' a combined strain relief and non- `-the conductors of theconductor cord 93 and of the power tool are'rst connected with the switch 94 and this assembly is then slipped into place onto the tool handle 90 from the bottom thereof. 'I'he unit 81 is' thereupon fastened in place by a bolt 95 extending through the sidesof the'handle 90 and the molded portion 9|, as shown in Figure 13. In addition, resilient connection is provided betweenthe unit 81 and handle 90 by means of lateral grooves formed in thehandle portion 9| which cooperate in interlock relationshipwith inwardly extending' angesor ribs 96/ of the support unit embodying 4our invention designed.

for this type of service is designated in its entirety at 1|. The device asillustrated is mounted on the inside of a pressed metal leg 12 which mightr be the leg of a.'r washing machine or'other handle 90, as shown in Figuresf12 and 13.

'I'his arrangement not onlyserves to form a part of the handle of the power tool, which may be conveniently and securely gripped, but also v provides shock protection for the switch 94 in case thepower tool is vdropped or otherwise misused. y'Il'he power tool is conveniently controlled by a trigger 98 which turns the switch 94 off and on.

In Figures 14 'and 15 anotheriform of combined strain relief `and non-rigid switch support adapted device. `The unit 1|comprises a switch housing 13 having a sleeve 14,'formed .integrally on the underside thereof, which is adapted to be connected to the conductor cord 15 to accomplish a strain relief function.l A switch 16 is carried in a recess formed in the housing 13. yOne terminal of the switch is connected to one conductork f of the conductor cord 15 while' the other kterminal is connected to a conductor projecting through the top ofthe housing 13. The unit 1| may be molded as one body around the cordconto be used in connection with a differentl form of handley |0| for a vpower tool is indicated in its entirety at |00., The unit |00 is in the form of a handle cap with a'conductor lcord strain relief sleeve |03 formed integrally on the lower end thereof. i The unit |00 may be formed as one body and'integrally molded onto a cord'conductor |04 extending through the 'sleeve |03.and cap portion |02, as shown. A switch |05 provided in the handleof the power tool is rst connected to the conductors ofthe cord |04and then the ccmbined unit is assembled onv the handle |0| and held in. place as by thebolts .|06 and |01. 'I'he ductor 15 and thethreeconductors 19, A|l0,-and

8|, as shown.f M v.

' The handle 82 of 'the switch 16 projects through an opening 83 provided in the leg 12, and

switch |05 is convenientlyfpositioned in place in vthe handle |0|Jby means of a member ||0 pro,-

vided on the right side thereof which is adapted y to t' into a corresponding recess formed in the the assembled device is held in place thereon by' a pair of bolts 84 passing through the leg 12 andi` switch housing 13, as shown. The left face of the switch housing 13y is undercut around .the

opening for the switch 16to provide a recess for K receiving a retaining plate 85 fastened ony the left side of the switch 16.' -By this arrangement,

the switch 16 is readily assembled and'supported in proper position in the switch housing 13'in cooperation` with the bolts 84 extending through the plate 85. v n K- By tightening the nuts 86 provided on the right ends ofthe bolts 84, the switch housing`13 may be drawn tightly against the inside of theleg handle |,0|, ras shown. A trigger operating the switch provides a convenient arrangemen for controlling the'povvertool.y

It will be notedthat in yeach of the above described forms of combined strainrelief and nonrigidswitch support units, the strain relief function is not only provided .bythe cord conductor` sleeves,` vbut alsokby the different resilient switch receiving bodies. yThese switch receiving bodies k further rserve to protect the yswitch therein from y shockand to eliminate a rigid connection ben tween the ,switches and the handles or support q members. The combined-strain reliefv and switch 4support units 8l and |00, described in connection withv Figures'l'l and 14, respectively, also have the additional function of forming part of the handles of the powerI tools with which they are used. 1

Where integral connections between the various parts of the different combined strain relief vand non-rigid switchsupport units have been specifled, such as between the conductor sleeves and cords, these integral connections are intended to `include those provided by cementing as well as those formed bymolding. f l

If desired various portions of the combined f strain relief and switch support units may be v made of rigid material although the advantages of the invention can best be realized by the use of structures which are completely resilient. Furthermore, the completely resilient construction facilitates the assembly of the switch support and lstrain relief with the apparatus with which they are used. The completely resilient constructions also serve to'assure the attainment of the maximum possible strain relief function andthe maximum possible function of the conductor cords. v

It will be evident to those skilled in the art that a large number of variations andmodiiications of the device of the present invention are possible, and that they may be applied to a great number of portable or semi-portable electrical appliances.

Since certain furtherchanges may be made in the foregoing constructions and different embodiments of the invention may be had without departing from the scope thereofit is intended that all matter described hereinbefore or shown in the accompanying drawings shall be interconductor cord connected to said switch, and a combined strain relief and switch support comprising a body of resilient, molded material with a cavity formed therein for receiving and supporting said switch, means for mounting said combined strain relief and switch support on said rigid support, and a resilient sleeve projecting as anl integral part of said body of resilient molded material and integrally attached to said conductor cord to provide a strain relief connection therefor. f

5.- In combination, a rigid support, a switch, a

conductor cord connected to said switch, and a combined strain relief and switch support comprising a body of resilient, molded material with a cavity formed therein for receiving and supporting said switch, deformable means integral with said body of resilient, molded material for engaging said rigid support Vand mounting said combined strain relief and switch support. thereon, and a resilient sleeve projecting integrally from said body of resilient, molded material and integrally attached to said conductor cord to provide a strain relief connection therefor.

6. In combination, an electrical appliance handle which is generally tubular in form and which is provided with'a slot adjacent one end thereof, a switch, a conductor cord connected to said switch, and a combined strain relief and switch support comprising a body of resilient, molded material with a cavity formed therein for receiving and supporting said switch, deformable means integral with said molded resilient body for interlocking with said slot in said tubular handle, and a resilient sleeve projecting integrally from said molded, resilient body and molded preted as illustrative and not in a limiting sense.

We claim the following as our invention:

l. In combination with an electrical appliance adapted to be moved around while connected for energization to a source of electrical current, a switch on the appliance for turning the same on and off, conductor means for connecting said switch to said source of electrical current, and a combined strain relief 'and switch support comprising a body of resilient, molded material having a cavity formed therein for receiving and supporting said switch, said molded resilient body being integrally attached to said conductor means to provide strain relief connection therewith.

2. In combination with an electrical appliance adapted to be moved around while connected for energization to a source of electrical current, a switch cn the appliance for turning the same on and'oif, a conductor cord for connecting said switch to said source of electrical current, and a combined strain relief and switch support comprising a body of resilient, molded material having a cavity-formed thereinv for receiving and supporting said switch and having a resilient sleeve projecting integrally therefrom, said sleeve being molded onto said conductor cord to provide strain relief connection therewith.

3. In combination, a rigid support, a switch, a conductor cord connected to said switch, a combined strain relief and switch support comprising a body of resilient, molded material having a cavity formed therein for receiving and supporting said switch, and means for mounting said combined strain relief and switch support on saidrigid support, said combined strain relief and switch support being integrally attached to said conductor cord to accomplish strain relief connection therewith.

4. In combination, a rigid support, a switch, a

onto said conductor cord, said handle, slot, and body being soy proportioned that said switch serves to retain said deformable means in interlock relationship with said handle.

7.- In combination, -a rigid support member having an aperture therein, a switch, a conductor cord connected to said switch, and a combined strain relief and switch support which comprises a. casing of resilient, molded material for housing and supporting said switch, a resilient sleeve projecting integrally from said casing and molded onto said conductor cord to provide a strain relief connection therefor, and a relatively heavy, resilient, overturned lip projecting integrally from said casing and interlocking with the edges of said aperture in` said rigid support member so as to non-rigidly attach said combined strain relief and switch support to one side of said rigid support member, said resilient switch casing, said sleeve, and said attaching lip being molded together as an integral body.

8. In combination, a rigid plate support member having an aperture therein, a switch, a conductor cord connected to said switch, and a combined strain relief and switch support which comprises a switch receiving member of resilient, molded material for receiving and supporting said switch, la resilient sleeve projecting integrally from said switch receiving member and molded onto said conductor cord to provide a strain relief connection therefor, an undercut, deformable collar portion extending from said Vswitch receiving member and adapted to fit in said aperture in said plate support member for the purpose of resiliently attaching said combined strain relief and switch support to one side of said support member.

9. In combination, a handle frame of a power tool, a switch, a conductor cord connected to said n strain relief and switch support which comprises switch, and a combined strain relief and switch .support forming part of the handle of said power tool and comprising a switch holding portionkfor resiliently supporting said switch on said handle frame and for protectively covering the same, and a resilient sleeve rojecting integrally from said switchl holding portion and molded onto` said connector cord in strain relief connection therewith, said switch holding portion and said conductor cord sleeve being molded together in Lan integral body.

10. In combination, a rigid support, a switch, a conductor cord connected to said switch, and a combinedstrain relief and switch support which comprises a body of resilient, molded material having a cavity. formed therein for receiving and supporting said switch and deformable means integral with said bo'dy of resilient,molded matea casing of resilient, molded material for housing 'and supporting said switch and a relatively heavy, resilient, overturned lip projecting integrally fromsaid casing and interlocking with the f edges ofsaid' aperture in said rigid support member so as .to non-rigidly attach said combined 4strain relief and switch support to one side ofv said rigid support member, saidresilient switch ductor cord connected to said switch, and a comrial for engaging said rigid supportA and mounting said combined strain relief and switch support thereon, said body of resilient, molded material being integrally attached to said conductor cord to provide a. strain relief connectiontherefor.

11. In combination, an electrical yappliance handle which is generally tubular in form which is provided with a slot adjacent one end thereof, a switch, a conductor cord connected to said switch, and a combined strain relief andswitch support which comprises a body of resilient,y molded material having a cavity formed therein for receiving and supporting said switch and deformable means integral with said molded resilient body for interlocking with said slot in said tubular handle, said handle, slot, and body'beingv s0 proportioned that said switch serves to retain said deformable means in interlock relationship l with said handle.

12. In combination, a rigid support member having an aperture therein, a' switch, a conductor cord connected to said switch, and a combined bined strain relief and switch support' which comprises a switch receiving member of resilient,

molded material for receiving and supporting said switch, and an undercut deformable, collar portion extending from said switch receiving member and adapted to fit into said aperture and said plate support member for the purpose of lresiliently attaching said combined strain relief and switch support to one side of said support o member, said combined strain relief and switch support being integrally attached to saidcon'- ductorcord to providea strain relief connection therewith. y

` 14. In combination, a handle frame of a power tool, a switch, aconductor cord connected to said switch, and a. combined strain relief and switch support` forminga par-tof the handle f said power tool and-comprising a body "of resilient, molded material having ajcavity formed therein for receiving and supporting said switch, lsaid ymolded resilient body beingv integrally attached to said conductor cordk to provide a strain relief HENRY` A; NE1L. ROBERT K. scHELKE. 

